Capacity
Augmentation & Energy Saving Project (ESP) at Vijaipur
In the FY 2012-13,
Company has successfully commissioned Capacity Enhancement & Energy Savings
projects along with installation of Carbon Dioxide Recovery plant at its
Vijaipur – I & Vijaipur – II units. These projects involved investment of
about ₹650 crore.
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Pre-revamp capacity
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Post-revamp capacity
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Incremental production
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Urea – I
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2620 MTPD
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3030 MTPD
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410 MTPD
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Urea – II
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2620 MTPD
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3231 MTPD
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611 MTPD
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Annual basis (Urea
– I&Urea– II)
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17.29 LMT
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20.66 LMT
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3.37 LMT
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The total annual
Urea capacity of the company after completion of these revamps of Vijaipur-I
& II has been increased by 3.37 LMT to overall 35.68 LMT.
In addition to the
augmentation of installed Urea capacity, Company has also achieved reduction in
specific energy consumption per MT of Urea produced
Conversion of Fuel Oil based
plants at Panipat, Bathinda & Nangal to Natural gas feedstock
Company has
implemented the following capital schemes for feedstock conversion from Fuel
Oil to Natural gas at Panipat, Bathinda & Nangal involving a total
investment of ₹ 4066 Crore.
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Ammonia Plant Feedstock
conversion project
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Panipat &
Bathinda
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Nangal
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LSTK
Contractor
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M/s Larsen & Toubro Mumbai
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Consortium of M/s Tecnimont SpA, Italy
& M/s Tecnimont ICB, Mumbai
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Process
Licensor
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M/s Haldor
Topsoe, Denmark
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M/s Kellog Brown & Root, USA
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Post
revamp Ammonia capacity, MTPD
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900 for each Panipat & Bathinda
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950
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Zero
Date
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29th January 2010
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29th
January 2010
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Estimated
Project Cost, Rs. Crore
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2587 (Panipat & Bathinda combined)
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1479
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Commissioning
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January 2013
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April 2013
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These feedstock
conversion projects involved changeover of feedstock from FO/LSHS to
environment friendly energy resource i.e. NG/RLNG. These projects not only
resulted in better environment but also resulted in savings on account of
subsidy payoffs by GOI.
Long Term RLNG
(LTRLNG) agreements are in place to meet the gas requirements at Panipat,
Bathinda & Nangal plants.
Post Feedstock Changeover, all
the three plants at Panipat, Bathinda & Nangal are operating at more than
100% daily rated capacity within the design daily energy
Implementation of Energy Reduction Schemes at NFL Panipat, Bathinda & Nangal Units
As per New Urea
Policy-2015, NFL Panipat, Bathinda & Nangal Units have been placed under
Group –III for which the target energy norms for the year 2018-19 would be 6.5
Gcal/MT of Urea. However vide letter no: 12012/1/2015-FPP dated 28th Mar' 2018,
GoI has extended the energy norms for the units for a further period of two
years i.e., till 31st Mar’ 2020 & then further to 30.09.2020 with a penalty
of 2% for Yr: 2018-19, 5% for Yr: 2019-20 and 10% thereafter. Revised norms are
now effective from 01.10.2020.
In view of the
above, NFL is installing 1 (one) unit of Gas Turbo Generator (GTG) of 20 MW
capacity along-with 1 (one) unit of Heat Recovery Steam Generator (HRSG)
at Panipat, Bathinda & Nangal Units.
The estimated capex of these projects is around INR 675 crores. The subject
works has been awarded to M/s Thermax Limited, Pune on 01.02.2018. GTG-HRSG has
been commissioned at Bathinda & Nangal in May’21 whereas at Panipat same is
expected by Oct’21 subject to mobilization of foreign experts from M/s Siemens
Sweden for commissioning.
Implementation of Energy Reduction Schemes at NFL Vijaipur-I & II
Under New Urea Policy (NUP)-2015, Vijaipur-I & Vijaipur-II units
have been placed under Group-I with energy norm of 5.50 Gcal/MT. For
reduction of energy at Vijaipur-I and Vijaipur-II, the estimated capital
expenditure shall be around INR 234 crore.
Following four schemes are being implemented:
1. Switch over of Process condensate stripping process from low
pressure to MP Stripping Section in Ammonia Plant of Vijaipur-I.
2. Revamp/retrofit of Synthesis Gas Compressor and Turbine in
Ammonia Plant of Vijaipur-I.
3. Switch over of Condensing steam turbine drives to motor drives
of GV solution and Cooling Tower pumps in Ammonia Plant of Vijaipur-II.
4. Installation of VAM for Gas Turbine in Captive Power Plant, to
chill process air compressor suction air and 3rd stage suction of synthesis gas
compressor to 15 deg C in Viajipur-II.
The executions of above schemes are in progress. Major energy saving scheme i
(Revamp/retrofit of Synthesis Gas Compressor and Turbine in Ammonia Plant of
Vijaipur-I) has been implemented in September/October 2020. With the the
subject revamp NFL, Vijaipur-I has achieved energy saving of 0.15 Gcal/MT of
urea. Rest of the schemes will also be implemented in 2021-22.
PURGE
GAS RECOVERY PLANT AT VIJAIPUR – II
NFL has installed latest state of the art technology Purge Gas Recovery
(PGR) unit at its Vijaipur-II plant. The membrane based PGR unit helps in
recovery of Hydrogen from purge gases which in turns increase Ammonia
production by 80 MTPD besides reducing energy consumption of
Ammonia Plant. The PGR unit has been commissioned in 2016.
BENTONITE SULPHUR PLANT AT PANIPAT
Bentonite Sulphur
is a sulphur fertilizer that can be used as a source of plant nutrient and / or
as a soil amendment for correction of problem of alkali soils. In order
to meet the demand of Bentonite Sulphur to address the issue of Sulphur
deficiency in soil and to improve the top & bottom line, NFL has set up
Bentonite Sulphur plant at Panipat Unit with capacity of 25,000 MT per annum.
Foundation stone of the project was unveiled by Hon’ble Cabinet Minister
(C&F) on 8th September 2016. Bentonite Sulphur Plant at Panipat Unit has
been commissioned on 20th December 2017.
JOINT VENTURES
Revival of
Ramagundam unit of FCIL
The Company through a Joint Venture
Company namely Ramagundam Fertilizers & Chemicals Limited (RFCL) along with
EIL, FCIL and other partners for revival of closed Urea plant with annual
installed capacity of 12.71 LMT. The
cost of project was ` 6338.16 crore with equity participation of 26% each of NFL
and EIL, 11% each of FCIL and State of Telangana, 14.3% of GAIL and 11.7% of a Consortium led by M/s HTAS,
Denmark. The project was commissioned on 22-03-2021.
NFL has also been mandated to market 100% of Urea to be
produced by RFCL.
NFL in joint venture with M/s Engineers India Limited (EIL) &
Fertilizers Corporation of India Limited (FCIL) is undertaking the revival of
Ramagundam unit of FCIL. The revival project is conceived with setting up of
2200 MTPD Ammonia plant and 3850 MTPD Urea plant at the existing Fertilizer
complex of Ramagundam unit of FCIL.
The equity participation in the joint venture is 26% each by
NFL & EIL, 11% by FCIL and 11% by State Government of Telangana.
Project is being implemented through EPCM mode and M/s EIL
is the EPCM Contractor for the project. Zero date of the revival project was
declared as 25th Sept 2015 and is targeted to be completed by end of December
2018. The project is in progress.
NFL is also providing Manpower Management Consultancy
(MMC) services to RFCL. As per agreement, NFL is undertaking recruitment and
training of all such personnel mutually agreed by RFCL and NFL. In addition to
fresh recruitment NFL is also providing experienced manpower on secondment
basis to RFCL
